ESA signs carbon composites contracts

The upper stages of an Ariane rocket are commonly made of aluminium, but switching to carbon composites lowers cost and could yield an extra two metric tonnes of spare payload capacity.

Ulrich Scheib, Director Head of Strategy, Business Development and Space Programs at MT Aerospace, Daniel Neuenschwander, ESA Director of Space Transportation and Jean-Christophe Henoux, Vice President Future Programmes at ArianeGroup signed at ESA Headquarters in the French capital.

This low-cost lightweight Phoebus demonstrator introduces carbon composite materials, in particular for the metallic tanks containing the cryogenic propellants such as liquid hydrogen and oxygen, and for other primary and secondary structures.

Propelling innovation

Composites allow new architectures and combinations of functions, which are not possible using metallic materials, further optimising the entire upper stage architecture and refining propellant loading, as well as minimising surplus fuel.

ESA Project Manager Josef Wiedemann said: “Future composite upper stages will look very different to those of today. Carbon composites will replace much of the metal, thereby reducing the mass and offering new opportunities to redefine the architecture of the upper stage depending on mission requirements.”

The goal is to achieve optimum mass savings while ensuring propellant compatibility with these new materials, at a lower production cost.

Phoebus aims to bring the relevant cutting-edge technologies to a technical readiness high enough to deliver an integrated stage demonstrator for cryogenic ground testing purposes in 2022. This will validate the technologies in a representative environment providing the foundation to enter development of future lightweight, low-cost upper stages, with applications for Ariane 6 in 2025.

These activities are being carried out within ESA’s Future Launchers Preparatory Programme.

EPPM offers the European angle on the worldwide plastics industry. Each issue features key industry, materials, machinery and events news from around the world to keep you at the forefront of the industry.